PHYSICO-MECHANICAL PROPERTIES OF REFRACTORY BRICKS OF ILARO CLAY WITH BLEND OF MELON SHELL AND RICE HUSK ASHES
Keywords:
Refractory; clay; physico-mechanical; additives; Taguchi-Orthogonal.Abstract
Refractory bricks (RB) made from clay (kaolin) are widely utilized as linings in high thermal system where intense heat is desired. Melon Shell Ash (MSA) and Rice Husk Ash (RHA) have the potential to increase and stabilize the SiO2 and Al2O3 contents in kaolin due to appreciable percentages. This study examined the physico-mechanical properties of refractory bricks produced from Ilaro kaolin reinforced with MSA and RHA. Kaolin deposits from three locations in Ilaro, South West Nigeria were harvested. Taguchi Orthogonal array was adopted for the experimental design batch mix of kaolin, MSA, and RHA which were: 100:0:0 (EDm0); 75:12.5:12.5 (EDm1); 50:25:25 (EDm2); 25:37.5:37.5 (EDm3); 75:17.5:7.5(EDm4); 75:7.5:17.5 (EDm5); 50:35:15 (EDm6); 50:15:35(EDm7); 25:50:25 (EDm8) and 25:25:50 (EDm9) weight percentage compositions. The samples were then used to produce ten batches of RB. Key physico-mechanical and thermal properties including: Density (D), Porosity (P), Cold Crushing Strength (CCS), Drying Shrinkage (DS), Firing Shrinkage (FS), Thermal Shock Resistance (TSR), and refractoriness (R) on the RB were determined following standard procedures and codes. Results for D, P, and CCS of the RB were: 1.65±0.1 – 1.85±0.2 g/cm3, 28.2±0.1 – 50.4± 0.3%, and 14.45±0.1 – 22.5±0.2 MPa, respectively. Results for DS, FS, TSR, and R of the RB were: 0.87±0.1 – 2.23±0.2%, 0.45±0.1 – 1.83±0.3%, 22±0.1 - 29±0.2 cycles, and 1515±0.1 – 1551±0.3oC, respectively. Sample EDm4 with DS, FS, TSR and R values of 0.87%, 0.45%, 29 cycles and 1551oC respectively, had the best properties. The study found that Ilaro clay enhanced with MSA and RHA at an optimum ratio of 75:17.5:7.5 can be used for production of fireclay bricks for furnace linings.
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